Disposable diapers

ABSTRACT

Disposable diaper having a moisture absorbent fluff pad which is contoured in the crotch area and which is disposed between a facing sheet and a backing sheet, said facing sheet being adapted to contact the body of a child. Both the facing sheet and backing sheet have a basis weight in the range of approximately 1.0-2.0 ounces per square yard, and each are comprised of a batt of moisture-absorbent, self-sustaining, adhesively bonded, intermingled cellulosic fibers. The outer surface of the facing and backing sheets each have a pattern defined by ridges and valleys extending over substantially the entire surface of the batt, the density of the sheets in the regions of said valleys being greater than the density of the sheets in the regions of said ridges. A method for manufacturing the facing sheet and backing sheet of the disposable diaper by forming a randomly arranged, intermingled cellulosic fibrous batt having a basis weight of approximately 1.0 ounces per square yard, passing said batt through a nip defined between a patterned roll and a moistened rubber roll to provide a pattern in one surface of the batt and raise a nap on the other surface, spraying opposite surfaces of said batt with adhesive, drying said adhesive and setting said adhesive.

United States Patent [191 Krusko 51March 20, 1973 [73] Assignee: ScottPaper Company, Delaware County, Pa.

[22] Filed: March 30, 1970 [211 Appl. No.: 23,752

[75] Inventor:

[52] US. Cl ..l28/287 [51] Int. Cl. ..A6lf 13/16 [58] Field of Search128/284, 286, 287, 290, 296

[56] References Cited UNITED STATES PATENTS 3,072,123 1/1963 Davis128/284 3,612,055 10/1971 Mesek et a1. 128/287 2,549,982 4/1951 McKhannet al. 128/287 2,788,003 4/1957 Morin 128/284 2,862,251 12/1958Kalwaites ..128/29O W 3,402,715 9/1968 Liloia et a1. 3,426,756 2/1969Romanek 3,439,678 4/1969 Thomas 3,444,859 5/1969 Kalwaites 3,523,5368/1970 Ruffo 128/287 Primary Examiner-Charles F. RosenbaumAttorney-William J. Foley, Martin L. Faigus, John W. Kane, Jr. and JohnA. Weygandt [57] ABSTRACT Disposable diaper having a moisture absorbentfluff pad which is contoured in the crotch area and which is disposedbetween a facing sheet and a backing sheet, said facing sheet beingadapted to contact the body of a child. Both the facing sheet andbacking sheet have a basis weight in the range of approximately 1.0-2.0ounces per square yard, and each are comprised of a batt ofmoisture-absorbent, self-sustaining, adhesively bonded, intermingledcellulosic fibers. The outer surface of the facing and backing sheetseach have a pattern defined by ridges and valleys extending oversubstantially the entire surface of the batt, the density of the sheetsin the regions of said valleys being greater than the density of thesheets in the regions of said ridges. A method for manufacturing thefacing sheet and backing sheet of the disposable diaper by forming arandomly arranged, intermingled cellulosic fibrous batt having a basisweight of approximately 1.0 ounces per square yard, passing said battthrough a nip defined between a patterned roll and a moistened rubberroll to provide a pattern in one surface of the batt and raise a nap onthe other surface, spraying opposite surfaces of said batt withadhesive, drying said adhesive and setting said adhesive.

39 Claims, 4 Drawing Figures PATENTEUMARZOIHTS SHEETlOF 2 PZwSEBOMozzzmom mm INVENTORS. MICHAEL Y- CHAN EVELYN H- KRUSKO BY ALLAN w.KLESIUS ATTORNEY.

PATENTEDMARZOIUYS ,721,242

SHEET 2 BF 2 INVENTORS. MICHAEL Y. CHAN EVELYN H. KRUSKO BY ALLAN w.KLESIUS DISPOSABLE DIAPERS BACKGROUND OF THE INVENTION A demand existsfor a disposable diaper of the nonl0 flushable, throwaway type which isinexpensive and possesses the mechanical and physical properties toperform as well, or better, than conventional textile cloth diapers. Anon-flushable, throwaway diaper which is intended to serve as asatisfactory replacement for the conventional textile cloth diapershould have sufficient strength in both the dry and wet condition toretain its shape, sufficient abrasion resistance to prevent the surfaceadjacent the baby from shredding or pilling up and sufficientflexibility to be worn comfortably. In addition, the disposable diapershould closely resemble a conventional textile cloth diaper in hand feeland appearance, and should be low cost to justify disposing of thediaper after each use.

Prior art non-flushable, throwaway diapers have not been commerciallyaccepted to any substantial degree. This lack of acceptance is believedto be attributable to the inability of others to produce a producthaving the requisite mechanical and physical properties to replaceconventional textile cloth diapers.

A representative prior art non-flushable throwaway diaper is disclosedin US. Pat. No. 3,402,7l5, issued to I Liloia et al., taken inconjunction with abandoned application Ser. No. 515,874, which isreferred to in the Liloia et al patent. This prior art diaper has anabsorbent fluff pad sandwiched between a pair of non-woven fabricsformed predominately of short cellulosic fibers, such as wood pulp orcotton linters, and the remainder of the fibers are longer syntheticfibers such as rayon. This diaper does not possess sufficient drytensile strength and wet tensile strength to perform satisfactorilyunless an excessive quantity of adhesive is utilized. Excessivequantities of adhesive will impair flexibility and cause a reduction inthe fluid retaining capacity of the cover material. Also, excessiveadhesive application may impair the surface feel characteristics of thecover sheet.

SUMMARY OF THE INVENTION The disposable diaper of this invention iscomprised of a moisture absorbent pad sandwiched between a nonwovenfacing sheet, and a backing sheet. In the preferred embodiment of theinvention, the backing sheet is identical in construction to the facingsheet; however, the backing sheet could be a thin film of waterproof,flexible material such as polyethylene, vinyl plastic, etc. In thepreferred embodiment of the invention the facing sheet and backing sheetare each defined by a substantially rectangular nonwoven,moisture-absorbent, self-sustaining, adhesively bonded, fibrous batt ofrandomly arranged, intermingled cellulosic fibers predominatelyconsisting of short wood pulp fibers and the moisture absorbent pad iscontoured to provide a reduced width in the crotch area. The outwardlyfacing surfaces of each nonwoven batt is provided with an embossedpattern therein defined by a plurality of ridges and valleys extendingover substantially the entire surface area of the batt, the density ofsaid batt in the regions of said valleys being greater than the densityof said batt in the regions of said ridges. The embossed pattern isproduced by passing said batt through a nip defined between a patternedroll and a substantially smooth-surfaced roll such as one made ofrubber. Sufficient pressure is applied to the rolls to insure that thepattern is retained in the fibrous batt during subsequent operations.After the embossed pattern is formed in the batt an adhesive, such as anacrylic latex, is sprayed on opposed surfaces of said batt to enhancethe strength and abrasion resistance of the batt, while not destroyingthe hand and flexibility thereof. By applying adhesive to the batt afterembossing, the batt was approximately 30 percent stronger than a battwhich was embossed after the adhesive was applied to opposed surfaces ofsaid batt and cured. The embossing operation compresses the fibers ofthe batt into close proximity with respect to each other, and therefore,the adhesive is more effectively utilized to bond fibers together thanwhen said adhesive is applied to an unembossed batt.

In the preferred embodiment of the invention, the patterned roll isprovided with a terry cloth pattern, which is formed in the roll by aphotoengraving process which utilizes the negative of a photograph of aterry cloth pattern. After embossing the fibrous batt has the physicalappearance of a terry cloth woven product. In this embodiment, theextremely close pattern of ridges and valleys making up the terry clothpattern provides excellent abrasion resistance to the fabric. Otherpatterns such as straight line regions of alternating ridges and valleyssimulating a corduroy pattern can also be impressed into the fibrousbatt.

The nonwoven facing and backing sheets of the disposable diaper of thisinvention are manufactured by forming a bonded batt of randomlyarranged, intermin gled fibers comprised of predominately shortcellulosic fibers, such as wood pulp fibers, and the remainder of saidbatt is comprised of longer synthetic fibers, such as high tenacityrayon fibers. The batt is then passed through the nip defined between apatterned roll and a rubber roll, moisture being added to the surface ofthe rubber roll to moisten the fibrous batt as it passes through thenip. Applying moisture to the batt enhances the ability of the batt toretain the embossed pattern therein during subsequent operations,andqalso aids in releasing the batt from the rolls. The side of the battwhich contains the rubber roll is provided with a loose fiber nap whichis capable of mechanically interlocking with a loose fiber nap of a likebatt, or with the fibers of the absorbent pad of the diaper. Aftertheembossing operation the patterned batt passes adhesiveapplying stationswhereat an adhesive, such as an acrylic latex, is sprayed onto oppositesurfaces of said batt. A vacuum assist is provided at eachadhesive-applying station to insure that adequate adhesive penetrationinto the batt occurs, and to minimize back-splash and adhesive drift.After the adhesive has been sprayed on the opposed surfaces of thefibrous batt, the batt is transported through an oven wherein the battis dryed and the adhesive is set. The finished nonwoven fabric is thenwound into a roll for subsequent use in the manufacture of disposablediapers and the like.

It is an object of this invention to provide a disposable diaper of thethrowaway type which has sufficient strength and abrasion resistance toserve as a replacement for conventional textile diapers.

It is a further object of this invention to provide a throwaway diaperhaving excellent hand feel and drape characteristics.

It is a further object of this invention to provide a throwaway diaperhaving a textile fabric appearance.

It is a further object of this invention to provide a throwaway diaperwhich is extremely absorbent.

It is a further object of this invention to provide a throwaway diaperhaving a moisture absorbent inner pad covered on at least one sidethereof by a nonwoven, moisture absorbent facing sheet.

It is a further object of this invention to provide a throwaway diaperhaving a nonwoven facing sheet, one side of which is provided with anembossed pattern defined by a plurality of ridges and valleys, thedensity of the facing sheet in the regions of said valleys being greaterthan the density of the facing sheet in the regions of said ridges.

It is a further object of this invention to provide a throwaway diaperhaving a water repellent backing sheet.

It is a further object of this invention to provide a throwaway diaperhaving a nonwoven randomly arranged, intermingled cellulosic fiber battas a backing sheet thereof, said backing sheet being chemically treatedwith a moisture repellent material.

It is a further object of this invention to provide a throwaway diaperhaving a facing sheet defined by a bonded fibrous batt of randomlyarranged, intermingled cellulosic fibers, said batt being provided withan embossed relief pattern in its outer surface thereof, which extendsover substantially the entire surface of the batt, and a second embossedpattern extending through said facing sheet and into a moistureabsorbent pad over which said facing sheet is disposed to providemechanical entanglement between the fibers of the facing sheet and thefibers of the moisture absorbent pad whereby fluid communication throughsaid facing sheet intosaid pad, and also along said pad and facing sheetare enhanced.

It is a further object of this invention to provide a method formanufacturing a facing sheet of a throwaway diaper wherein an adhesiveis applied to an embossed fibrous batt of randomly arranged,intermingled cellulosic fibers, and said adhesive is subsequently driedand set.

It is a further object of this invention to provide a method formanufacturing a facing sheet of a throwaway diaper wherein a fibrousbatt is moistened by water sprayed upon the surface of a rubber rollwhich defines, in conjunction with a patterned embossing roll, a nipregion through which said fibrous batt passes.

Other objects and advantages of this invention will be readilyunderstood by referring to the detailed description which follows takenin conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic representationof the sequential steps performed in manufacturing a nonwoven covermaterial for a throwaway diaper;

FIG. 2 is an enlarged sectional view along line 2--2 of FIG. 1 showingdetails of construction of the nonwoven facing sheet utilized in thedisposable diapers of this invention;

FIG. 3 is a perspective view of the disposable diaper of this invention;and

FIG.;4 is a sectional view taken along line 4-4 of FIG. 3, with thespecific embossed pattern shown in FIG. 2 omitted for purposes ofclarity.

DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION The method ofmanufacturing a moisture absorbent, nonwoven, self-sustaining, absorbentfabric suitable for use as a cover material in disposable diapers andthe like can best be understood by referring to the schematicrepresentation of the process shown in FIG. 1. A loosely compacted,randomly arranged, intermingled fibrous batt 10, comprised ofapproximately percent wood pulp fibers and approximately 25 percentlonger synthetic fibers, such as rayon, is formed by conventionalweb-forming equipment which does not form a part of the presentinvention but which will be discussed briefly for purposes of clarity.Baled rayon is opened by feeding it through a Rando Prefeeder and RandoOpener-Blender, both of which are manufactured by the CurlatorCorporation of Rochester, New York. A continuous roll of pulp lap isfiberized by passing it through a fiberizer, such as the onemanufactured by Joa, Inc. of North Wales, Fla. The opened rayon fibersand defibered wood pulp fibers are blended in a Rando Feeder, and areair-laid by a Rando Webber to form a randomly arranged, intermingledfibrous batt containing approximately 75 percent wood pulp fibers and 25percent rayon fibers and having approximately 8 percent moisture regain.The Rando Feeder and Rando-Webber are manufactured by the CurlatorCorporation. The wood pulp lap preferably is provided with a suitabledebonding agent to insure that the pulp lap can be uniformly defiberedin the fiberizer.

In the preferred embodiment of the invention, a high wet modulus rayonof 1.5 denier and 1 9/16 inch length is used; however, other syntheticfibers can be utilized. A high wet modulus rayon fiber can be purchasedfrom FMC Corporation and is designated as FMC Fiber 410.

The fibrous batt can be formed with a basis weight up to about 2 ouncesper square yard; however, in the preferred embodiment of the inventionthe fibrous batt, as initially formed by the Rando-Webber, has a basisweight in the range of approximately 0.9-1.l ounces per square yard.

The fibrous batt formed by the web forming equipment is embossed on onesurface 32 (FIG. 2) thereof by feeding said batt through a nip definedbetween an upper patterned roll 12 and a lower rubber roll 14. In thepreferred embodiment of this invention, the upper pattern roll 12 isloaded by hydraulic cylinders to provide the necessary pressure to formthe embossed pattern in the batt 10. Moisture is sprayed from a nozzle16 onto the surface of rubber roll 14 just prior to the nip, whereby themoisture is transferred from the rubber roll to the batt 10 as the battpasses through the nip to insure that the pattern formed in said battwill be retained therein duringsubsequent operations and to aid inreleasing the web from the rolls. In the event that the initially formedbatt 10 has sufficient moisture to retain an embossed pattern thereinduring subsequent operations, the application of moisture prior toembossing can be eliminated.

In the preferred embodiment of the invention, a terry cloth pattern isformed on the surface of roll 12 by a photoengraving process well knownin the art. It is understood that other patterns and other methods ofapplying a pattern to a roll can be utilized. The patterned embossingroll is heated by steam within the range of approximately 190F to 2 l0F,and a pressure of the order of magnitude of 0.5 to 20 pounds per linearinch is applied at the nip of rollers 12 and 14.

The temperature of the embossing roll 12 can be varied depending uponthe particular embossing pressure imposed on the batt 10, i.e., lowertemperatures can be used with increasing pressures. In addition, variouspercentages of moisture add-on can be applied through nozzle 16,depending on the pressure-temperature parameters of the embossing step,i.e., lower percentages of moisture can be utilized by increasing theembossing pressure and/or temperature. The moisture level of the battmust be sufficient to insure that the batt will retain its embossedpattern during subsequent operations.

After the pattern has been embossed into the upper surface 32 of theweb, the batt is fed past successive adhesive-applying stations. At thefirst station, adhesive is applied to the lower surface of the webthrough an adhesive nozzle 18, and a vacuum assist is provided from theopposite side of said batt to improve adhesive penetration and minimizebacksplash and adhesive drift. At the second adhesive-applying station,the adhesive is sprayed onto the upper surface 32 of the batt 10 throughan adhesive spray nozzle 22, and a vacuum assist 24 is provided from theopposite side of the batt for the same reason that the vacuum assist 20is provided at the first adhesive-applying station.

In the preferred embodiment of this invention a self cross-linkableacrylic latex sold by Rohm & Haas under the trade name Rhoplex HA8 isutilized. The total adhesive solids add-on is approximately 8-12 percentby weight.

After the batt 10 has passed the second adhesive-applying station, it isfed through an oven 26 which is maintained at approximately 300F to drythe web, and subsequently at about 320F to cure said web. The web, \asit enters the oven has approximately 200 percent moisture add-on byweight which resulted from the moisture application through nozzle 16and the moisture application through adhesive nozzles 18 and 20. Thedryed and cured batt is then rolled in a roll 28 for subsequent use as anonwoven cover material for disposable diapers.

Although the self cross-linkable acrylic latices are preferred in themanufacture of the nonwoven fabric of this invention, other adhesivesmay be utilized, and when other adhesives are utilized the batt 10 willbe subjected to an adhesive-setting process appropriate for theparticular adhesive used.

It is highly desirable to utilize a predominate amount of wood pulpfibers in the nonwoven fabric of this invention, since wood pulp isrelatively inexpensive as compared to the cost of longer textile fibers,such as rayon and cotton, and since wood pulp has excellent absorbencycharacteristics.

The nonwoven cover material formed according to the above-describedmethod has a basis weight up to or about 2.0 ounces per square yard, butpreferably is in the range of approximately 1.1 to approximately 1.6ounces per square yard. Manufacturing a nonwoven fabric of predominatelyshort cellulosic fibers, such as wood pulp, in the basis weight rangereferred to above, requires extreme care in handling during thefabrication thereof. This is particularly true prior to embossing atwhich time the formed batt 10 has relatively little integrity. Byapplying moisture from nozzle 16 onto the surface of rubber roll 14 fortransfer to the batt 10, instead of applying moisture directly againstthe surface of the web, the batt is not physically disturbed, andtherefore the chance of destroying the uniformity of the batt isreduced.

The fiber construction in the finished fabric is shown in FIG. 2. Thefinished fabric has an upper embossed surface 32 which is defined by thepattern contained in the outer periphery of pattern roll 12, and alower, loose fiber nap surface 30 formed by its engagement with theperiphery of rubber roll 14 during the embossing operation. The functionof the loose fiber nap surface 30 will be described in detail withrespect to the disposable diaper construction shown in FIGS. 3 and 4.

Referring to FIGS. 3 and 4, the diaper 40 of this invention is comprisedof a moisture absorbent pad 46 extending longitudinally along the centerof the diaper and adapted to fit between the legs of an infant in thecrotch area. The pad 46 is preferably made of fluffed wood pulp fibers,and is contoured in the crotch area to define an hourglass configurationfor reducing unneeded bulk to provide comfort for the baby. Theabsorbent pad is sandwiched between a facing sheet 42 adapted to bepositioned against the skin of the baby, and a backing sheet 44. In thepreferred embodiment of the invention, both the facing sheet 42 and thebacking sheet 44 are comprised of randomly arranged intermingledcellulosic fibers manufactured according to the process described indetail, supra and both the facing and backing sheets are substantiallyrectangular as is shown in FIG. 3. v

To prevent moisture strikethrough during use of the diaper, a fluidimpermeable material, such as polyethylene can be placed between theabsorbent fluff pad 46 and the backing sheet 44, or to retard the rateof moisture strikethrough, the backing sheet 44 may be coated orchemically treated in a suitable manner to render it substantially waterimpermeable. For example, a material such as an emulsion of wax andpoly(vinyl acetate) sold by Du Pont under the trade name Nalan GN isextremely effective for retarding moisture strikethrough when applied toboth surfaces of the backing sheet 44.

The outer surfaces of facing sheet 42 and backing sheet 44 are providedwith the embossed pattern formed by embossing roll 12, and therefore,the loose fiber nap layer 30 of the facing sheet 42 faces thecorresponding loose fiber nap surface 30 of the backing sheet 44. Whenthe sheets are assembled to produce disposable diaper 40, the fibers ofthe loosely napped surfaces tend to mechanically interlock with eachother and with the fibers of the absorbent fluff pad 46 to therebyprovide a relatively stable product. In addition, any suitable adhesive,such as hot melt can be utilized to bond the facing sheet to the backingsheet, and to retain the fluff pad 46 in proper position therebetween.

To enhance the capillary flow characteristics between the facing sheet42 and the absorbent pad 46, a substantially broad pattern is embossedinto the absorbent pad 46 through the facing sheet 42, to definecompressed lines 54, and high loft, bulk regions 52. This embossedpattern produces a continuous fiber network between the facing sheet 42and the fluff in the compressed regions 54 to enhance the fluiddistribution along lines 54 and into the fluff pad 46. As can be seen inFIG. 3, two sets of spaced, continuous embossed lines 54 are formed inthe facing sheet and underlying absorptive layer 46. One of the sets ofembossed lines 54 extends in the long direction of the diaper, and thesecond set of embossed lines extends substantially transverse to thefirst set of embossed lines.

In the preferred embodiment of the invention, the backing sheet 44 has alongitudinal length slightly in excess of the longitudinal length offacing sheet 42, and the end portions of the backing sheet 44 are foldedover the upper surface of facing sheet 42 to provide strengthenedregions 48 and 50 for receiving pins. Alternatively, the facing sheetand backing sheet can be manufactured of the same length, and a printbonded pattern can be applied to the longitudinally spaced edges of thediaper to provide the needed pin strength, or alternatively a gauzeinsert can be sandwiched between the sheets at the longitudinally spacededges to provide the necessary pin strength.

What is claimed is: 4

l. A throw-away diaper having an elongate absorbent layer disposedbetween a facing sheet and a backing sheet, said facing sheet being softand moisture pervious; said elongate absorbent layer having a transversedimension defined by spaced, elongate said margins, at least a portionof said side margins being recessed to define a narrow crotch regionadapted to be positioned in the perineal region of a wearer; said facingand backing sheets having side margins extending transversely beyond thespaced side margins of said absorbent layer and having a substantiallyuniform transverse dimension in the region of the diaper disposed inlongitudinal alignment with the recessed portions of the side margins ofsaid absorbent layer.

2. The throw-away diaper according to claim 1, wherein said absorbentlayer is comprised of a fluff batt of wood pulp fibers.

3. The throw-away diaper according to claim 2, wherein said facing sheetand said backing sheet are substantially rectangular.

4. The throw-away diaper according to claim 3, wherein said elongateabsorbent layer has a forward region and a rearward region disposed,respectively, on opposite sides of the crotch region, said forwardandrearward regions having a greater transverse dimension than said crotchregion.

5. The throw-away diaper according to claim 3, wherein said backingsheet is comprised of a thin plastic water repellent material.

6. A throw-away diaper according to claim 1, wherein said facing sheetcomprises a moisture absorbent, self-sustaining, adhesively bonded,fibrous batt including randomly arranged, intermingled cellulosicfibers, said batt having a substantially uniform weight of fibers perunit area throughout substantially its entire extent, an embossedpattern providing a plurality of ridge regions and valley regionsextending over substantially its entire extent, the density of saidfacing sheet in the regions of said valleys being greater than thedensity of said facing sheet in the regions of said ridges.

7. The throw-away diaper according to claim 6, wherein said backingsheet is comprised of a thin plastic water-repellent material.

- 8. A throw-away diaper according to claim 6, wherein said facing sheetcomprises up to about 30 percent long reinforcing fibers, and theremainder of said facing sheet comprises relatively short cellulosicfibers.

9. The throw-away diaper according to claim 8, wherein the shortcellulosic fibers of said facing sheet are wood pulp fibers.

10. The throw-away diaper according to claim 9, wherein said reinforcingfibers are rayon.

11. The throw-away diaper according to claim 10, wherein said adhesiveis a cross-linkable acrylic latex.

12. The throw-away diaper according to claim 9, wherein said facingsheet has a basis weight up to about 2 ounces per square yard.

13. The throw-away diaper according to claim 12,

15. The throw-away diaper according to claim 14,.

wherein said backing sheet is comprised of a thin plastic waterrepellent material.

16. The throw-away diaper according to claim 14, wherein said secondembossed pattern is comprised of spaced, continuous embossed lines insaid facing sheet and elongate absorbent layer.

17. The throw-away diaper according to claim 16, comprising two sets ofspaced, continuous embossed lines, one of said sets of embossed linesbeing disposed transversely to the other of said sets of embossed lines.

18. The throw-away diaper according to claim 17, wherein said backingsheet is water repellent.

19. A throw-away diaper according to claim 6, wherein said backing sheetis comprised of a selfsustaining, adhesively bonded, fibrous battincluding randomly arranged, intermingled cellulosic fibers.

20. The throw-away diaper according to claim 19, wherein said backingsheet contains a water-repellant agent.

21. A throw-away diaper according to claim 1, wherein said elongateabsorbent layer has a forwardregion and a rearward region disposed,respectively, on opposite sides of the crotch region, said forward andrearward regions having a greater transverse dimension than said crotchregion.

bonded, fibrous batt including randomly arranged, intermingledcellulosic fibers, said batt having a substantially uniform weight offibers per unit area throughout substantially its entire extent, a firstembossed pattern disposed only in said fibrous batt providing aplurality of ridge regions and valley regions extending oversubstantially the entire extent of said facing sheet, the density ofsaid facing sheet in the regions of said valleys being greater than thedensity of said facing sheet in the region of said ridges, and a secondembossed pattern impressed into said facing sheet and underlyingmoisture-absorbent layer whereby the moisture absorption rate into andalong said facing sheet and moistureabsorbent layer is enhanced.

24. The throw-away diaper according to claim 23, wherein said facingsheet comprises up to about 30 percent long reinforcing fibers, and theremainder of said facing sheet comprises relatively short cellulosicfibers.

25. The throw-away diaper according to claim 24, wherein said facingsheet has a basis weight of up to about 2.0 ounces per square yard.

26. The throw-away diaper according to claim 25, wherein said facingsheet has a basis weight approximately in the range of 1.1 1.6 ouncesper square yard.

27. The throw-away diaper according to claim 24, wherein said shortcellulosic fibers are wood pulp fibers.

28 The throw-away diaper according to claim 27, wherein said longreinforcing fibers are rayon fibers.

29. The throw-away diaper according to claim 28, wherein across-linkable acrylic latex bonds the fibers in said facing sheet.

30. The throw-away diaper according to claim 28, wherein said elongateabsorbent layer has a transverse dimension defined by spaced, elongateside margins, at least a portion of said side margins being recessedtoward each other to define a narrow crotch region adapted to bepositioned in the perineal region of a wearer.

31. The throw-away diaper according to claim 24, wherein said elongateabsorbent layer has a transverse dimension defined by spaced, elongateside margins, at least a portion of said side margins being recessedtoward each other to define a narrow crotch region adapted to bepositioned in the perineal region of the wearer.

32. The throw-away diaper according to claim 23, wherein said backingsheet is comprised of a self sustaining, adhesively bonded, fibrous battof randomly arranged, intermingled cellulosic fibers.

33. The throwaway diaper according to claim 23, wherein said backingsheet is water repellent.

34. The throw-away diaper according to claim 23, wherein said secondembossed pattern provides spaced, continuous compressed lines in saidfacing sheet and said moisture-absorbent layer.

35. The throw-away diaper according to claim 23,

wherein said second embossed pattern provides two sets of spaced,continuous embossed lines in said facing sheet and saidmoisture-absorbent layer, the embossed lines in one of said setsextending substantially transverse to the embossed lines in the other ofsaid sets.

36. The throw-away diaper according to claim 23, wherein said elongateabsorbent layer has a transverse dimension defined by spaced, elongateside margins, at least a portion of said side margins being recessedtoward each other to define a narrow crotch region adapted to bepositioned in the perineal region of a wearer.

37. A throw-away diaper according to claim 36, wherein said elongateabsorbent layer has a forward region and a rearward region disposed,respectively, on opposite sides of the crotch region, said forward andrearward regions having a greater transverse dimension than said crotchregion.

38. The throw-away diaper according to claim 36, wherein said secondembossed pattern is impressed into said facing sheet substantially onlyin regions overlying said elongate absorbent layer.

39. The throw-away diaper according to claim 38, wherein said elongateabsorbent layer is a fluff batt of cellulosic fibers.

2. The throw-away diaper according to claim 1, wherein said absorbentlayer is comprised of a fluff batt of wood pulp fibers.
 3. Thethrow-away diaper according to claim 2, wherein said facing sheet andsaid backing sheet are substantially rectangular.
 4. The throw-awaydiaper according to claim 3, wherein said elongate absorbent layer has aforward region and a rearward region disposed, respectively, on oppositesides of the crotch region, said forward and rearward regions having agreater transverse dimension than said crotch region.
 5. The throw-awaydiaper according to claim 3, wherein said backing sheet is comprised ofa thin plastic water repellent material.
 6. A throw-away diaperaccording to claim 1, wherein said facing sheet comprises a moistureabsorbent, self-sustaining, adhesively bonded, fibrous batt includingrandomly arranged, intermingled cellulosic fibers, said batt having asubstantially uniform weight of fibers per unit area throughoutsubstantially its entire extent, an embossed pattern providing aplurality of ridge regions and valley regions extending oversubstantially its entire extent, the density of said facing sheet in theregions of said valleys being greater than the density of said facingsheet in the regions of said ridges.
 7. The throw-away diaper accordingto claim 6, wherein said backing sheet is comprised of a thin plasticwater-repellant material.
 8. A throw-away diaper according to claim 6,wherein said facing sheet comprises up to about 30 percent longreinforcing fibers, and the remainder of said facing sheet comprisesrelatively short cellulosic fibers.
 9. The throw-away diaper accordingto claim 8, wherein the short cellulosic fibers of said facing sheet arewood pulp fibers.
 10. The throw-away diaper according to claim 9,wherein said reinforcing fibers are rayon.
 11. The throw-away diaperaccording to claim 10, wherein said adhesive is a cross-linkable acryliclatex.
 12. The throw-away diaper according to claim 9, wherein saidfacing sheet has a basis weight up to about 2 ounces per square yard.13. The throw-away diaper according to claim 12, wherein said facingsheet has a basis weight in the range of approximately 1.1-1.6 ouncesper square yard.
 14. The throw-away diaper according to claim 6, havinga second embossed pattern in said facing sheet and underlying elongateabsorbent layer, whereby the moisture absorption rate into and alongsaid facing sheet and underlying absorbent layer is enhanced.
 15. Thethrow-away diaper according to claim 14, wherein said backing sheet iscomprised of a thin plastic water repellent material.
 16. The throw-awaydiaper according to claim 14, wherein said second embossed pattern iscomprised of spaced, continuous embossed lines in said facing sheet andelongate absorbent layer.
 17. The throw-away diaper according to claim16, comprising two sets of spaced, continuous embossed lines, one ofsaid sets of embossed lines being disposed transversely to the other ofsaid sets of embossed lines.
 18. The throw-away diaper according toclaim 17, wherein said backing sheet is water repellent.
 19. Athrow-away diaper according to claim 6, wherein said backing sheet iscomprised of a self-sustaining, adhesively bonded, fibrous battincluding randomly arranged, intermingled cellulosic fibers.
 20. Thethrow-away diaper according to claim 19, wherein said backing sheetcontains a water-repellant agent.
 21. A throw-away diaper according toclaim 1, wherein said elongate absorbent layer has a forward region anda rearward region disposed, respectively, on opposite sides of thecrotch region, said forward and rearward regions having a greatertransverse dimension than said crotch region.
 22. The throw-away diaperaccording to claim 1, wherein said backing sheet is comprised of a thinplastic water repellent material.
 23. A throw-away diaper or the likehaving an elongate, moisture-absorbent layer disposed between a backingsheet and a facing sheet, said facing sheet being a moisture absorbent,self-sustaining, adhesively bonded, fibrous batt including randomlyarranged, intermingled cellulosic fibers, said batt having asubstantially uniform weight of fibers per unit area throughoutsubstantially its entire extent, a first embossed pattern disposed onlyin said fibrous batt providing a plurality of ridge regions and valleyregions extending over substantially the entire extent of said facingsheet, the density of said facing sheet in the regions of said valleysbeing greater than the density of said facing sheet in the region ofsaid ridges, and a second embossed pattern impressed into said facingsheet and underlying moisture-absorbent layer whereby the moistureabsorption rate into and along said facing sheet and moisture-absorbentlayer is enhanced.
 24. The throw-away diaper according to claim 23,wherein said facing sheet comprises up to about 30 percent longreinforcing fibers, and the remainder of said facing sheet comprisesrelatively short cellulosic fibers.
 25. The throw-away diaper accordingto claim 24, wherein said facing sheet has a basis weight of up to about2.0 ounces per square yard.
 26. The throw-away diaper according to claim25, wherein said facing sheet has a basis weight approximately in therange of 1.1 - 1.6 ounces per square yard.
 27. The throw-away diaperaccording to claim 24, wherein said short cellulosic fibers are woodpulp fibers. 28 The throw-away diaper according to claim 27, whereinsaid long reinforcing fibers are rayon fibers.
 29. The throw-away diaperaccording to claim 28, wherein a cross-linkable acrylic latex bonds thefibers in said facing sheet.
 30. The throw-away diaper according toclaim 28, wherein said elongate absorbent layer has a transversedimension defined by spaced, elongate side margins, at least a portionof said side margins being recessed toward each other to define a narrowcrotch region adapted to be positioned in the perineal region of awearer.
 31. The throw-away diaper according to claim 24, wherein saidelongate absorbent layer has a transverse dimension defined by spaced,elongate side margins, at least a portion of said side margins beingrecessed toward each other to define a narrow crotch region adapted tobe positioned in the perineal region of the wearer.
 32. The throw-awaydiaper according to claim 23, wherein said backing sheet is comprised ofa self-sustaining, adhesively bonded, fibrous batt of randomly arranged,intermingled cellulosic fibers.
 33. The throw-away diaper according toclaim 23, wherein said backing sheet is water repellent.
 34. Thethrow-away diaper according to claim 23, wherein said second embossedpattern provides spaced, continuous compressed lines in said facingsheet and said moisture-absorbent layer.
 35. The throw-away diaperaccording to claim 23, wherein said second embossed pattern provides twosets of spaced, continuous embossed lines in said facing sheet and saidmoisture-absorbent layer, the embossed lines in one of said setsextending substantially transverse to the embossed lines in the other ofsaid sets.
 36. The throw-away diaper according to claim 23, wherein saidelongate absorbent layer has a transverse dimension defined by spaced,elongate side margins, at least a portion of said side margins beingrecessed toward each other to define a narrow crotch region adapted tobe positioned in the perineal region Of a wearer.
 37. A throw-awaydiaper according to claim 36, wherein said elongate absorbent layer hasa forward region and a rearward region disposed, respectively, onopposite sides of the crotch region, said forward and rearward regionshaving a greater transverse dimension than said crotch region.
 38. Thethrow-away diaper according to claim 36, wherein said second embossedpattern is impressed into said facing sheet substantially only inregions overlying said elongate absorbent layer.
 39. The throw-awaydiaper according to claim 38, wherein said elongate absorbent layer is afluff batt of cellulosic fibers.